Antimicrobial application system with recycle and capture

ABSTRACT

A capture unit for use with an antimicrobial application unit may include an upstream filter and a downstream filter. The upstream filter may be positioned to receive effluent from the application unit and to filter solid components from the effluent. The resultant upstream effluent filtrate may then be passed downstream to the downstream filter. The downstream filter may be used to filter an antimicrobial component from the upstream effluent filtrate and the resultant downstream effluent filtrate may be suitable for disposal as wastewater discharge. The antimicrobial is preferably a quaternary ammonium compound, is more preferably an alkylpyridinium chloride, and is most preferably cetylpyridinium chloride.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/069,255, filed Mar. 14, 2016, which is a divisional of U.S. patentapplication Ser. No. 14/510,385, filed Oct. 9, 2014, which issued asU.S. Pat. No. 9,352,983 on May 11, 2016, which is a continuation-in-partof U.S. patent application Ser. No. 10/535,030, filed Oct. 10, 2008,which issued as U.S. Pat. No. 9,072,315 on Jul. 7, 2015, which is theNational Stage of International Patent Application No.PCT/US2003/035933, filed Nov. 12, 2003, and which claims the benefit ofU.S. Provisional Application No. 60/425,679, filed Nov. 12, 2002.

BACKGROUND

This invention relates to an antimicrobial application system, and moreparticularly to an antimicrobial application system with recyclefeatures for use in connection with food products and surfaces and otheritems associated with food processing.

Antimicrobial application systems, including spray cabinets are known inthe art. U.S. Pat. No. 6,742,720, issued Jun. 1, 2004, titled Sprayapplication System, discusses a number of such systems and highlights anumber of the advantages and disadvantages of these systems. Thedisclosure of U.S. Pat. No. 6,742,720 is incorporated herein byreference. The spray application systems disclosed in that patent offera number of advantages over earlier systems, as discussed in more detailin that patent. Still, the present inventors have further refined andbuilt upon those systems to offer alternate embodiments offeringadditional flexibility. For example, it may be desirable to recycle theantimicrobial that is applied to the work pieces. Adding equipment andsteps to allow for recycling adds to the cost and complexity of asystem, so it will not always be preferred. Still, using recyclingreduces consumption of the antimicrobial and water and reduces theamount of waste material in need of disposal. This may be desirable forany number of reasons such as environmental concerns, raw materialcosts, raw material storage limitations, disposal costs, and regulatoryissues involving disposal of wastewater and some antimicrobials.Accordingly, under many circumstances, it will be desirable to recyclethe antimicrobial for multiple applications to work pieces to betreated.

Recycling of liquids applied to some types of work pieces in a processline is generally known in the art. Still, recycling liquids inconnection with food processing and items associated with foodprocessing presents a number of special issues and concerns,particularly concerning adulteration, contamination, andcross-contamination. These concerns typically argue against recycling orlead to the use of slow, cumbersome, undesirable extra steps and extraequipment that add to the cost and complexity of a system. One suchcomplex system is disclosed in U.S. Pat. No. 6,348,227, issued toCaracciolo, Jr. in 2002, the disclosure of which is incorporated hereinby reference.

SUMMARY

In one aspect, a capture unit for use with an antimicrobial applicationunit includes an upstream filter and a downstream filter. The upstreamfilter may be configured to be coupled to an upstream capture line forcarrying effluent from the antimicrobial application unit to theupstream filter. The downstream filter may be configured to be coupledto a downstream capture line for carrying the upstream effluent filtrateto the downstream filter. The upstream filter may be further configuredto filter a solid component of the effluent and the downstream filtermay be further configured to filter an antimicrobial component of theeffluent.

In various embodiments, the upstream filter may comprise a screen filterthat includes a body having a first end, a second end, and an annularwall extending therebetween. The annular wall may define a bore thatextends through the body for receiving the effluent from the upstreamcapture line. The annular wall may comprise a filter portion having aplurality of perforations extending through the annular wall to filter asolid component of the effluent when the effluent is received within thebore from the upstream capture line. The body may be rotatable about arotation axis extending through the bore. The annular wall may furthercomprise a band portion having a continuous surface along the inwardlyfacing surface and extending about the bore. The band portion may beconfigured to receive the effluent from the upstream capture line ontothe continuous surface before the effluent passes to the filter portion.The screen filter may further comprise a thread protruding from theinwardly facing surface of the annual wall into the bore and thathelically extends along the inwardly facing surface between the firstend and the second end of the body. The annular wall may furthercomprise a delivery region configured to receive the effluent from theupstream capture line. The delivery region includes a continuous surfaceforming a band along the inwardly facing surface and extending about thebore. The thread may extend along the filter portion and the continuoussurface. The screen filter may further comprise a cleaner configured toremove filtered solid components from the annular wall. The cleaner maycomprise a spray bar including one or more fluid ports positioned todirect fluid toward the annular wall. The fluid ports may be positionedoutside the bore.

In various embodiments, the downstream filter comprises at least twofilter units, each comprising a container configured to retain a filtermaterial comprising activated carbon. The filter units may be aligned inseries and configured to filter the antimicrobial component from theupstream effluent filtrate. In one application, the antimicrobialcomponent comprises a quaternary ammonium compound. At least one of thefilter units may include a header comprising a body having an upstreaminlet and a plurality of downstream fluid ports positioned along aplurality of arms. In one embodiment, the body may comprise at leastfour arms arranged in an “X” configuration. In one embodiment, the bodyincludes at least two arms, each defining at least twenty fluid ports.The fluid ports may be positioned on at least two sides of each arm. Thefluid ports may define cross-sections between 0.125 to 0.250 inches. Atleast one of the containers may comprise an inner surface formed of aplastic.

In another aspect, an antimicrobial carbon filtration system comprises aheader. The header may include a body having an upstream inlet and aplurality of downstream fluid ports positioned along a plurality ofarms. The header may be configured to be positioned at an upstreamportion of a filter container to distribute a fluid containing anantimicrobial component to be separated onto a filter material.

In one embodiment, the body may include at least two arms, each definingat least twenty fluid ports. The fluid ports may be positioned on atleast two sides of each arm. The fluid ports may further definecross-sections between 0.125 to 0.250 inches. In one embodiment, theheader may comprise at least four arms arranged in an “X” configuration.In a further embodiment, the body may include four arms arranged in an“X” configuration and the fluid ports may define cross-sections between0.125 to 0.250 inches.

In yet another aspect, an antimicrobial carbon filtration systemcomprises a filter unit container. The filter unit container may have anouter wall and a plastic inner wall. The plastic inner wall may define abore configured to retain a filter material comprising activated carbon.

In various embodiments, the outer wall comprises a metal drum. Thefilter unit container may further comprise a removable liner and theremovable liner may comprise the inner wall. The outer wall may beformed of plastic and the filter unit container may comprise a plasticdrum.

BRIEF DESCRIPTION OF THE DRAWINGS

The above brief description, as well as further objects, features andadvantages of the present embodiments will be more fully appreciated byreference to the following detailed description of the presentlypreferred but nonetheless illustrative embodiments in accordance withthe present embodiments when taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a schematic view of an antimicrobial application systemaccording to various embodiments described herein;

FIG. 2 is a side elevation view of a portion of a recycle unit accordingto various embodiments described herein;

FIG. 3 is a schematic view of an antimicrobial application systemaccording to various embodiments described herein;

FIG. 4 is a schematic view of a capture unit according to variousembodiments described herein;

FIG. 5 is a semi-schematic view of a capture unit according to variousembodiments described herein;

FIG. 6 is a semi-schematic view of a capture unit according to variousembodiments described herein;

FIG. 7 is a perspective view of a header according to variousembodiments described herein;

FIG. 8 is a perspective view of a filter unit according to variousembodiments described herein;

FIG. 9 is a perspective view of a filter unit container according tovarious embodiments described herein;

FIG. 10 is a perspective view of a filter unit container according tovarious embodiments described herein; and

FIG. 11 is a perspective view of a filter unit container according tovarious embodiments described herein.

DESCRIPTION

Various embodiments are described and illustrated in this specificationto provide an overall understanding of the composition, function,operation, and application of the disclosed compositions and methods. Itis understood that the various embodiments described and illustrated inthis specification are non-limiting and non-exhaustive. Thus, theinvention is not necessarily limited by the description of the variousnon-limiting and non-exhaustive embodiments disclosed in thisspecification. The features and characteristics illustrated or describedin connection with various embodiments may be combined with the featuresand characteristics of other embodiments. Such modifications andvariations are intended to be included within the scope of thisspecification. As such, the claims may be amended to recite any featuresor characteristics expressly or inherently described in, or otherwiseexpressly or inherently supported by, this specification. Further,Applicant reserves the right to amend the claims to affirmativelydisclaim features or characteristics that may be present in the priorart. Therefore, any such amendments comply with the requirements of 35U.S.C. §§ 112(a) and 132(a). The various embodiments disclosed anddescribed in this specification can comprise, include, consist of, orconsist essentially of the features and characteristics as variouslydescribed in this specification.

Also, any numerical range recited in this specification is intended toinclude all sub-ranges of the same numerical precision subsumed withinthe recited range. For example, a range of 1.0 to 10.0 is intended toinclude all sub-ranges between (and including) the recited minimum valueof 1.0 and the recited maximum value of 10.0, that is, having a minimumvalue equal to or greater than 1.0 and a maximum value equal to or lessthan 10.0, such as, for example, 2.3 to 6.6. Any maximum numericallimitation recited in this specification is intended to include alllower numerical limitations subsumed therein and any minimum numericallimitation recited in this specification is intended to include allhigher numerical limitations subsumed therein. Accordingly, Applicantreserves the right to amend this specification, including the claims, toexpressly recite any sub-range subsumed within the ranges expresslyrecited in this specification. All such ranges are intended to beinherently described in this specification such that amending toexpressly recite any such sub-ranges would comply with the requirementsof 35 U.S.C. §§ 112(a) and 132(a).

Any patent, publication, or other disclosure material identified in thisspecification is incorporated by reference into this specification inits entirety unless otherwise indicated, but only to the extent that theincorporated material does not conflict with existing descriptions,definitions, statements, or other disclosure material expressly setforth in this specification. As such, and to the extent necessary, theexpress disclosure as set forth in this specification supersedes anyconflicting material incorporated by reference into this specification.Any material, or portion thereof, that is said to be incorporated byreference into this specification, but which conflicts with existingdefinitions, statements, or other disclosure material set forth in thisspecification, is only incorporated to the extent that no conflictarises between that incorporated material and the existing disclosurematerial. Applicants reserve the right to amend this specification toexpressly recite any subject matter, or portion thereof, incorporated byreference into this specification.

The grammatical articles “one”, “a”, “an”, and “the”, as used in thisspecification, are intended to include “at least one” or “one or more”,unless otherwise indicated. Thus, the articles are used in thisspecification to refer to one or more than one (i.e., to “at least one”)of the grammatical objects of the article. By way of example, “acomponent” means one or more components, and thus, possibly, more thanone component is contemplated and may be employed or used in animplementation of the described embodiments. Further, the use of asingular noun includes the plural, and the use of a plural noun includesthe singular, unless the context of the usage requires otherwise.Additionally, the grammatical conjunctions “and” and “or” are usedherein according to their accepted usage. By way of example, “x and y”refers to “x” and “y”. On the other hand, “x or y” refers to “x”, “y”,or both “x” and “y”, whereas “either x or y” refers to exclusivity.

As herein described, an antimicrobial application system may beconfigured to recycle antimicrobial used in connection with foodprocessing. The recycling may include recycling of antimicrobial appliedto items associated with food processing for subsequent application ofthe recycled antimicrobial to items associated with food processing. Theantimicrobial application system may include an antimicrobialapplication unit and a recycle unit. An initial, dilute antimicrobialcomposition may be prepared and the concentration of the antimicrobialmay be controlled automatically by a control unit. The control unit mayinclude or be operatively controllable by a processor. The processor maybe configured to access a data storage medium having stored thereininstructions executable by the processor to perform one or moreoperations of the antimicrobial application system. The antimicrobialcomposition may be provided to the antimicrobial application unit andapplied to work pieces, such as raw poultry carcasses. After applicationto the work pieces, the antimicrobial composition may flow to a recycletank of the recycle unit. The concentration of the antimicrobial in theantimicrobial composition flowing to the recycle tank may be monitoredmanually or by the system. Additional antimicrobial may be automaticallyadded if the concentration of the antimicrobial in the antimicrobialcomposition falls below a desired amount. All or a portion of theantimicrobial composition may be periodically diverted to a capture tankand selective removal of the antimicrobial composition from thecomposition. The removed antimicrobial and remaining composition arethen disposed of in appropriate manners. The antimicrobial is preferablya quaternary ammonium compound, an alkylpyridinium chloride, orcetylpyridinium chloride.

In various embodiments, the antimicrobial application system may beconfigured to perform or achieve one or more of the following: reductionof raw material consumption without sacrificing safety; providing forperiodic, batch style separation and disposal of spent antimicrobial;automatically monitor and maintain a desired composition of theantimicrobial composition to be recycled; provide for improved recaptureand return of an antimicrobial composition applied to work pieces;automatically compensate for additional liquids passing from wetted workpieces to the recycled antimicrobial composition; capable of providingcontinuous, real-time monitoring and control of the composition of anantimicrobial composition; reduce waste leaving the system and wastedisposal costs associated therewith; provide a safe waste stream thatmay be safely drained into a wastewater system; increase the flexibilityand advantages of the spray application systems and spray cabinetsdisclosed in U.S. Pat. No. 6,742,720 and in PCT Application SerialNumber PCT/US03/35933; effectively apply, capture, and reapply asolution that is prone to foaming; provide increased flexibility inpositioning and utilization of spray nozzles; handle large fluctuationsin processing requirements; is relatively easy to install, clean, andmaintain; and provide a simple, reliable method of monitoring andcontrolling the composition of an antimicrobial to be recycled, evenwhen the antimicrobial contains impurities.

Referring to FIG. 1, the reference numeral 10 refers in general to anantimicrobial application system according to various embodiments. Theantimicrobial application system 10 generally comprises an antimicrobialapplication unit 12 and a recycle unit 14, and may include a captureunit 15.

The antimicrobial application unit 12 may take any number ofconfigurations. In the preferred embodiment, the antimicrobialapplication unit 12 takes the general form of one of the embodiments ofa spray application system as disclosed in U.S. Pat. No. 6,742,720. Onepossible exception is that the liquid barriers described in U.S. Pat.No. 6,742,720 are not used in a preferred embodiment. A conveyor 16passes through a housing 18 for moving workpieces 20, such as rawpoultry, through the housing 18. As described in more detail below, adrip tray or pan 22 extends downstream of the housing 18, disposed belowthe conveyor 16 and the workpieces 20 carried thereby. Examples of sprayapplication systems that might be used in connection with the presentembodiments are discussed in detail in U.S. Pat. No. 6,742,720 and willnot be discussed in more detail here. It is of course understood thatthe antimicrobial application unit 12 is not limited to thoseembodiments or to spray application systems in general. Theantimicrobial application unit 12 may apply a composition such as anantimicrobial composition to any number of different kinds and types ofworkpieces 20 in any number of different ways. Methods of applicationused by such an application unit 12 may include but are not limited tospraying, misting, fogging, immersing, pouring, dripping, andcombinations thereof. It is understood that the system 10 may be used totreat a wide variety of different workpieces 20, including but notlimited to meat, poultry, fish, fresh and salt water seafood, fruits,vegetables, other foodstuffs, animals, food packaging, and items andsurfaces related to food or food processing. It is also understood thatthe workpieces 20 may be live, dead, raw, hide-on, carcass, pieces,cooked, prepared, processed, partially processed, ready to eat, or readyto cook. It is further understood that the system 10 may be used totreat workpieces 20 completely unrelated to food or food processingitems.

A rigid member 24, such as stainless steel tubing, is affixed to thehousing 18, preferably at a downstream end of the housing 18. As bestseen in FIG. 3, the rigid member 24 has parallel arms 26 that arealigned on opposite sides of the conveyor line 16. A series of matchingopenings 28 are provided in each arm 26 for housing counters or sensors.Protective lenses 30 provide watertight seals, preferably NEMA 4 seals,to protect the counters from damage that might otherwise occur under theharsh washdown conditions to which the systems 10 are routinelysubjected. Three counters are preferably provided in series. As bestseen in FIG. 1, the arms 26 are disposed so that the counters arealigned to detect the presence or absence of workpieces 20. The use ofthree counters provides redundancy and increases accuracy. In thatregard, the counters are operably connected to a controller such as acentral control unit 32 or 164, and the counts taken by the threecounters are continuously compared. If one counter provides a reading orcount that differs from that provided by the other two, the centralcontrol unit 32 or 164 will typically be programmed to disregard thereading of the inconsistent counter and rely instead upon the readingsof the other two counters. The logic and interpretation of the differentreadings may of course be modified in any number of ways.

The recycle unit 14 dilutes a concentrated antimicrobial composition orsolution to obtain a dilute antimicrobial composition or solution andprovides the dilute antimicrobial solution to the antimicrobialapplication unit 12. An antimicrobial source, such as a supply tank 34,is connected to the housing 18 via antimicrobial supply line or conduit36. A chemical feed pump 38 is disposed in antimicrobial supply line 36.The pump 38 is operably connected to a controller 40 for reasons to bedescribed below. The antimicrobial preferably comprises a quaternaryammonium compound, more preferably comprises an alkylpyridiniumchloride, and most preferably comprises cetylpyridinium chloride. Moreparticularly, the concentrated antimicrobial solution preferablycomprises a concentrated solution of a quaternary ammonium compound asdescribed in U.S. patent application Ser. No. 09/494,374, filed on Jan.31, 2000 by Compadre et al. The disclosure of U.S. patent applicationSer. No. 09/494,374 (Compadre et al.) is incorporated herein byreference. The concentrated solution preferably comprises anantimicrobial and a solubility enhancing agent, and the solubilityenhancing agent preferably comprises propylene glycol. The quaternaryammonium compound is preferably present in the concentrated solution ina weight percent of approximately 40%, and the solubility enhancingagent is preferably present in the concentrated solution in a weightpercent of approximately 60%. It is of course understood that any numberof different antimicrobials and solubility enhancing agents may be used,and the concentrated and dilute solutions may have any number ofdifferent components and compositions, including but not limited to thecomponents and compositions of the concentrated and dilute solutionsdisclosed in U.S. patent application Ser. No. 09/494,374 (Compadre etal.). Concerns of adulteration, contamination, or cross-contaminationare eliminated or alleviated because of the broad-spectrum efficacy ofthe preferred antimicrobial solutions and because of the filtration andautomatic concentration measures.

One or more recycle tanks 42 are provided. A return line or conduit 44extends between the housing 18 and the recycle tank 42 for passingliquid from the housing 18 to the tank 42. Multiple return lines 44 maybe used to connect multiple antimicrobial application units 12 to therecycle tanks 42. A filter 46 is disposed in the housing 18 or in thereturn line 44. The filter 46 is preferably a wire mesh filter, such asa 100 mesh filter, sized to capture visible particulate matter in theeffluent from the antimicrobial application unit 12. Visible particulatematter in the effluent will typically be minimal because of upstreamwashing that will typically be performed on the workpieces 20. First andsecond filters 48 and 50 are associated with each tank 42 and aredisposed between the tank 42 and a system pump 52 to provide forparallel flow between the tank 42 and the system pump 52. Valves 54 orother means are provided for selectively directing liquid passing fromthe tank 42 to the system pump 52 through either the first filter 48 orthe second filter 50. This allows the system 10 to continue operatingwhile one of the filters 48 or 50 is being cleaned, replaced, orrepaired. A three-way valve 56 is disposed in conduit 58 for reasons tobe discussed below. A purge or capture line 60 passes from the valve 56to the capture tank 62. A capture pump 64 is disposed in capture line60. Although the recycle tank 42 may include an impeller or some otherstirring or agitation means, no such stirring or agitation means is usedin the preferred embodiment. A feed line 66 passes from the system pump52 to the housing 18 and is connected to one or more sprayers 68.Multiple feed lines 66 may be used, or the feed line 66 may be branchedor divided, if desired, to connect the recycle tank 42 to multipleantimicrobial application units 12. A bypass conduit 70 having a reliefvalve 72 is disposed in the feed line 66. A diverting line 74 is alsodisposed in the feed line 66. The diverting line 74 is connected to adilution pump 78 and has a pressure regulator 80 disposed therein.

A source of potable water 82, such as tap water, is connected to therecycle tank 42 via water supply line or conduit 84. A diverting line 86is also disposed in water supply line 84. The diverting line 86 isconnected to a dilution pump 88 and has a pressure regulator 90 disposedtherein. The pressure regulators 80 and 90 preferably regulate thepressure in lines 74 and 86 to a pressure lower than the pressures inlines 66 and 84 and preferably regulate the pressure in lines 74 and 86down to approximately 15 psig. The dilution pumps 78 and 88 areelectrically interlocked to provide for matched, stroke for strokepumping action. The dilution pumps 78 and 88 are also sized to providefor a desired, fixed dilution ratio. The dilution ratio is preferablyless than or equal to approximately 1 part dilute composition to 1 partwater, is more preferably less than or equal to approximately 1 partdilute composition to 30 parts water, and is most preferably less thanor equal to approximately 1 part dilute composition to 60 parts water.Conduits 92 and 94 exit the dilution pumps 78 and 88 and are disposed toroute liquids from the dilution pumps 78 and 88 to a static mixer 96.The static mixer is preferably an inline, auger style static mixer.

A sensor 98 is disposed at the discharge end of the static mixer 96. Inthe preferred embodiment, the sensor 98 is an ultraviolet lightspectrophotometer or UV spec sensor. Of course it is understood that anynumber of different types of sensors 98 may be used, including but notlimited to infrared, visible light, or ultraviolet sensors. The sensor98 is capable of detecting the concentration of the antimicrobial in thesolution exiting the static mixer 96. The controller 40 operablyconnects the sensor 98 to the chemical feed pump 38. The controller 40is capable of receiving a signal from the sensor 98 and sending acorresponding on/off signal to the chemical feed pump 38. A dischargeline 100 passes from the sensor 98 to the capture or purge tank 62.

A siphon 102 is disposed in the capture tank 62 and is connected to adrain line 104. The drain line 104 passes from the capture tank 62 to anantimicrobial separation unit 106. The antimicrobial separation unit 106preferably comprises one or more filters 108 or filter units eachcomprising a container dimensioned to retain a volume of filtermaterial, such as disposable carbon filters, that selectively remove theantimicrobial from the composition. An intermediate filter line 109connects the filters 108. A disposal line 110 exits the antimicrobialseparation unit 106 for disposing of water and any other componentsremaining after the antimicrobial is selectively removed. It isunderstood that a separation unit 106 may or may not be used and thatany number of different separation methods may be used. It is alsounderstood that filters 108 may be disposable or reusable.

The central control unit 32 is used to control the entire system 10. Thecentral control unit 32 may perform various tasks or functions inassociation with operation of the system 10. For example, the centralcontrol unit 32 may operatively associated with system processes tocollect, process, and/or communicate data indicative of operationalstates, system conditions, triggering events, component functions,events, or other like data. One or more sensors, such as sensor 98, maybe operatively associated with the central control unit 32 to detect andto provide signals indicative of system operation conditions orconditions in connection with operation of the system 10, for example.In one embodiment, the central control unit 32 is programmed toactivate, deactivate, or modulate system pumps or valves, to receive,transmit, and/or process data signals in communication with one or morecomponents of the system 10, or to process or analyze data communicatedfrom one or more sensors operatively associated with various units ofthe system. For example, the sensor 98 or another sensor may beconfigured to detect contaminants or other aspects of fluid compositionassociated with the fluid recycled through the system 10. The centralcontrol unit may include one or more processors or computer systemsprogrammed with software, firmware, or other computer-executableinstructions to perform the various functions of the control module. Thecentral control unit 32 may be operatively associated with one or moredata transmission devices which may receive and/or store data receivedor processed by the central control unit 32. In certain embodiments, thecentral control unit 32 may communicate signals to one or moreindicators which reflect the activity or function of different aspectsof the system 10. For example, one such indicator may include a warninglight, or an alert graphical display associated with a local or remoteplant monitor.

In operation, a dilute antimicrobial solution will typically be preparedand used for one spray cycle that will typically last for one day. Thedilute antimicrobial solution will then be discarded, disposed of, orremoved from the system 10 for further processing. It is of courseunderstood that the spray cycle may be of any number of differentdurations. It is also understood that the system 10 may be operated inbatch mode, in steady-state mode, or in any number of different types orcombinations of modes of operation. A new spray cycle will typicallybegin each morning with an empty and clean recycle tank 42 and an emptyand clean capture tank 62. Before the antimicrobial application unit 12is activated, and before the system pump 52 is turned on, the diluteantimicrobial solution is prepared. In that regard, a desired amount oftap water is fed to the recycle tank 42. The recycle tank 42 ispreferably filled to approximately one third to approximately one halfof its capacity with potable water. The concentration pump 38 isactivated to feed the concentrated antimicrobial composition to thehousing 18, where it drains through return conduit 44, and to therecycle tank 42, until a predetermined amount of the concentratecomposition is provided. The concentrate composition combines with thewater in the recycle tank 42 to form a dilute solution of the desiredconcentration. The desired ranges of the concentration of antimicrobialin dilute solution include but are not limited to the concentrationranges of the antimicrobial in the dilute solutions disclosed in U.S.patent application Ser. No. 09/494,374 (Compadre et al.).

Once the desired concentration is obtained in the recycle tank 42, thesystem pump 52 is activated, and the dilute solution is supplied to theantimicrobial application unit 12. The dilute solution provided to theantimicrobial application unit 12 is not potable. Still, contaminationor cross-contamination of the workpieces 20 is not a concern because ofthe safety and broad spectrum efficacy of the dilute antimicrobialsolution used. The recycle unit 14 supplies the dilute antimicrobialsolution to the antimicrobial application unit or units 12 at any numberof different flow rates and pressures. These flow rates and pressuresmay include, but are not limited to, the flow rates and pressuresdiscussed in U.S. Pat. No. 6,742,720. The bypass conduit 70 and reliefvalve 72 route a portion of the dilute composition to a lower portion ofthe housing 18 so that it does not pass through the sprayers 68 and isnot applied to the workpieces 20. The ratio of dilute compositionpassing through the bypass conduit 70 versus passing to the sprayers 68will typically be greater than or equal to approximately 1:1 and willmore typically be greater than or equal to approximately 2:1. The dilutecomposition passing through the bypass conduit 70 provides for improvedmixing of the captured composition and any concentrate composition thatmight be added. The use of the bypass conduit 70 and relief valve 72provides greater flexibility in providing dilute composition to sprayers68 at or within desired pressure ranges. The use of the bypass conduit70 and relief valve 72 also makes it easier to continue to providedilute composition to the sprayers 68 at consistent pressure asadditional spray application units 12 are brought online or takenoffline and regardless of the number of spray application units 12 thatare online.

Once the recycle unit 14 is supplying the dilute antimicrobial solutionto the antimicrobial application unit 12, the workpieces 20 to beprocessed, such as raw poultry, are moved by the conveyor 16, throughthe housing 18, and the dilute antimicrobial solution is applied to theworkpieces 20, such as by spraying. The portion of the diluteantimicrobial solution that does not adhere to the workpieces 20collects in a drain and is returned via return line 44, through filter46, and to the recycling tank 42 for reuse. The length of the drip tray22 is selected so that it will catch drops from workpieces 20 exitingthe housing 18 for approximately 1 minute after the workpieces 20 exitthe housing 18. This enhances the recovery of the dilute antimicrobialsolution and reduces downstream losses. Although not preferred, liquidbarriers such as water spray curtains may be used in the housing 18.Also, the workpieces 20 may be wet from upstream washing, so additionalwater may enter the recycle tank 42, decreasing the concentration of theantimicrobial in the dilute solution.

It is desirable to avoid concentration spikes in the dilute composition,particularly in the dilute composition exiting the sprayers 68 andpassing through the diverting line 74 for routing to sensor 98.Accordingly, steps are taken to insure thorough mixing of the dilutecomposition being recycled between the recycle unit 14 and theantimicrobial application unit 12. This is one reason why theconcentrate supply line 36 routes the concentrated antimicrobialsolution to the housing 18 rather than directly to the recycle tank 42.By the time the concentrate composition mixes with dilute compositionsfrom the sprayers 68 and from the bypass line 70, passes through returnline 44, filter 46, recycle tank 42, filter 48 or 50, and system pump52, the resultant liquid is thoroughly mixed and has a relativelyuniform composition.

A preferred sensor 98, such as a spectrophotometer, is typically used tomeasure very low concentrations of a component in a composition. It istherefore important to provide a liquid that has not only has arelatively uniform composition but also a very low concentration of theantimicrobial or component to be measured. Often, it will not bepractical or feasible to obtain accurate, reliable readings for theantimicrobial at the concentration ranges typically found in the recycletank 42. Diluting the composition before taking a concentration readingwill offer greater flexibility in the selection of a sensor 98 formonitoring the concentration of the antimicrobial. Samples of thecomposition exiting the recycle tank 42 are therefore taken and furtherdiluted, to yield further diluted compositions in which theantimicrobial is present within a concentration range that is readilyand accurately measured by the sensor 98. The dilution ratio of thedilution pumps 78 and 88 is selected to provide the desired degree ofdilution, such as within the ranges discussed above. The pumps 78 and 88are set on a timer to take samples at a set interval, each sample beingtaken for a set duration of time. It is understood that theconcentration may be monitored at any number of different intervals andfor any number of different durations and that the concentration may becontinuously monitored. The electrically interlocked pumps 78 and 88provide the dilute composition and water in the desired fixed ratio tofurther dilute the dilute composition. Using electrically interlockedpumps at a desired, fixed dilution ratio simplifies controls needed tooperate the system 10. It is of course understood that the pumps neednot be interlocked, the dilution ratio need not be fixed, and any numberof different methods may be used to select, control, and adjust thedilution ratio as desired.

The dilute composition and water are combined and passed through thestatic mixer 96 to provide for thorough mixing, further reducing therisk of concentration spikes as the liquid passes the spectrophotometer98. The spectrophotometer 98 senses the concentration of theantimicrobial in the passing liquid. The sensor 98 is operably connectedto the controller 40. Accordingly, if the sensor 98 detects that theconcentration of antimicrobial falls below a desired amount, thecontroller 40 activates the chemical feed pump 38 to add more of theconcentrated antimicrobial solution into the housing 18 and to bring theconcentration of the antimicrobial in the dilute antimicrobial solutionback up to the desired level. The system 10 can be configured to allowthe potable water to be controlled in this fashion as well, but it isunlikely that there will be a need to add make-up water.

It is undesirable to route the highly diluted liquid that passes thesensor 98 back into the recycle tank 42, so it is routed to the capturetank 62. The siphon 102 in the capture tank 62 allows the liquid tocollect in the capture tank 62, until the liquid reaches a desiredlevel. When the liquid in the capture tank 62 reaches the desired level,the siphon 102 empties the capture tank 62, passing the liquid throughconduit 104 and to the disposable carbon filters 108 of theantimicrobial separation unit 106. The disposable filters 108 capturethe antimicrobial to selectively remove the antimicrobial from thesolution. Using the siphon 102 reduces or eliminates channeling problemsthat might otherwise arise if the liquid were allowed to continuouslydrip from the capture tank 62 onto the carbon filters 108.

At the end of the spray cycle, such as at the end of a shift or a day orother chosen period of time, the valve 56 is actuated to divert thedilute antimicrobial solution received from the recycle tank 42 to thecapture pump 64. The capture pump 64 empties the recycle tank 42 andpasses the dilute antimicrobial solution to the capture tank 62. Whenthe liquid reaches a desired level in the capture tank 62, the siphon102 routes the liquid through conduit 104 and to the disposable carbonfilters 108 of the antimicrobial separation unit 106. The disposablefilters 108 capture the antimicrobial to selectively remove theantimicrobial from the solution. When the antimicrobial impregnateddisposable filters 108 are spent, they are then disposed of in anappropriate manner, such as by incineration or disposal at an approvedlandfill. The remaining, relatively antimicrobial-free liquid is thendisposed of in an appropriate manner, such as by being drained into awastewater system of a plant. The frequency with which the system 10will need to be purged will depend upon any number of factors, such asthe number of workpieces 20 to be processed by the antimicrobialapplication unit 12 and the volume of the dilute antimicrobial solutionrequired to charge the system 10 at the beginning of a spray cycle. Aperiodic purge of the system 10 will typically be used.

An alternate embodiment of the antimicrobial application system 10 isdisclosed in FIG. 3. The antimicrobial application system 10 of thealternate embodiment also generally comprises an antimicrobialapplication unit 112 and a recycle unit 114 and will typically include acapture unit 115.

The antimicrobial application unit 112 may take any number ofconfigurations. For example, the antimicrobial application unit 112 maytake the general form of one of the embodiments of a spray applicationsystem as disclosed in U.S. patent application Ser. No. 10/001,896. Inthe preferred embodiment, spray containment barriers are not used. Aconveyor 116 passes through a housing 118 for moving workpieces 120,such as raw poultry, through the housing 118. As described in moredetail below, a drip tray or pan 122 extends downstream of the housing118, disposed below the conveyor 116 and the workpieces 120 carriedthereby. The spray application systems are discussed in detail in U.S.Pat. No. 6,742,720 and will not be discussed in more detail here. It isof course understood that the antimicrobial application unit 112 is notlimited to those embodiments or to spray application systems in general.The antimicrobial application unit 112 may apply an antimicrobial to anynumber of different types of workpieces 120 in any number of differentconventional ways. Methods of application used by such an antimicrobialapplication unit 112 may include but are not limited to spraying,misting, fogging, immersing, pouring, dripping, and combinationsthereof. It is understood that the system 10 may be used to treat a widevariety of different workpieces 120, including but not limited to meat,poultry, fish, fruits, vegetables, other foodstuffs, animals, foodpackaging, and items and surfaces related to food or food processing. Itis also understood that the workpieces 120 may be live, dead, raw,cooked, prepared, processed, partially processed, or ready to eat. It isalso understood that the system 10 may be used to treat workpieces 120completely unrelated to food or food processing items.

The recycle unit 114 dilutes a concentrated antimicrobial composition toobtain a dilute antimicrobial composition and provides the diluteantimicrobial composition to the antimicrobial application unit 112. Arecycle tank 124 is provided. The recycle tank 124 may include animpeller or some other stirring or agitation means. A source of potablewater 126, such as tap water, is connected to the recycle tank 124 viawater supply line 128. Similarly, an antimicrobial source, such as asupply tank 130, is connected to the recycle tank 124 via antimicrobialsupply line 132. The antimicrobial preferably comprises a quaternaryammonium compound, more preferably comprises an alkylpyridiniumchloride, and most preferably comprises cetylpyridinium chloride. Moreparticularly, the concentrated antimicrobial composition preferablycomprises a concentrated composition of a quaternary ammonium compoundas described in U.S. patent application Ser. No. 09/494,374, filed onJan. 31, 2000 by Compadre et al. The disclosure of U.S. patentapplication Ser. No. 09/494,374 (Compadre et al.) is incorporated hereinby reference. The concentrated composition preferably comprises anantimicrobial and a solubility enhancing agent, and the solubilityenhancing agent preferably comprises propylene glycol. The quaternaryammonium compound is preferably present in the concentrated compositionin a weight percent of approximately 40%, and the solubility enhancingagent is preferably present in the concentrated composition in a weightpercent of approximately 60%. It is of course understood that any numberof different antimicrobials and solubility enhancing agents may be used,and the concentrated and dilute compositions may have any number ofdifferent components and compositions, including but not limited to thecomponents and compositions of the concentrated and dilute compositionsdisclosed in U.S. patent application Ser. No. 09/494,374 (Compadre etal.). Concerns of contamination or cross-contamination are eliminated oralleviated because of the broad spectrum efficacy of the preferredantimicrobial compositions.

A chemical feed pump 134 is disposed in antimicrobial supply line 132. Asensor 136 is connected to the recycle tank 124 via lines 138 and 140.In the preferred embodiment, the sensor is an ultraviolet lightphotospectrometer or UV spec sensor. It is of course understood that anynumber of different sensors and any number of different light sensorsmay be used. For example, the light sensor may use light havingwavelengths that fall in any number of different ranges, including butnot limited to ultraviolet light, visible light, infrared light, andcombinations thereof. Of course it is understood that any number ofdifferent types of sensors 136 may be used, including but not limited toinfrared, visible light, or ultraviolet sensors. The sensor 136 iscapable of detecting the concentration of the antimicrobial in thecomposition in the recycle tank 124. A controller 142 operably connectsthe sensor 136 to the chemical feed pump 134. The controller 142 iscapable of receiving a signal from the sensor 136 and sending acorresponding on/off signal to the chemical feed pump 134. A feed line144 exits the recycle tank 124, passes through the system pump 146,through a valve 148, and connects to the antimicrobial application unit112. Multiple feed lines may be used, or the feed line 144 may bebranched or divided, if desired, to connect the recycle tank 124 tomultiple antimicrobial application units. The valve 148 is preferably athree-way valve. A return line 150 exits the antimicrobial applicationunit 112, passes through a filter 152, and connects to the recycle tank124. Multiple return lines may be used to connect multiple antimicrobialapplication units to the recycle tank 124. The filter 152 is preferablya wire mesh filter sized to capture visible particulates in the effluentfrom the antimicrobial application unit 112. Visible particulates in theeffluent will typically be minimal because of upstream washing that willtypically be performed on the workpieces 120. A capture line 154 passesfrom the valve 148 to a capture tank 156. A drain line 158 passes fromthe capture tank 156 to an antimicrobial separation unit 160. Theantimicrobial separation unit 160 preferably comprises one or moredisposable filters selected to separate the antimicrobial from water. Adisposal line 162 exits the antimicrobial separation unit 160 fordisposing of water after the antimicrobial is removed. A central controlunit 164 is used to control the entire system 10 and may be similar tothe central control unit 32.

In operation, a dilute antimicrobial composition will typically beprepared and used for one spray cycle that will typically last for oneday. The dilute antimicrobial composition will then be discarded,disposed of, or removed from the system 10 for further processing.Accordingly, each spray cycle, typically beginning each morning, beginswith an empty and clean recycle tank 124 and an empty and clean purge orcapture tank 156. Before the antimicrobial application unit 112 isactivated, and before the system pump 146 is turned on, the diluteantimicrobial composition is prepared. In that regard, a desired amountof tap water is fed to the recycle tank 124. The recycle tank 124 ispreferably filled to approximately one third to approximately one halfof its capacity with potable water. The central control unit 164activates the sensor 136 so that liquid from the recycle tank 124 passesthrough the sensor 136. The sensor 136 initially detects the absence ofantimicrobial (no absorbance at 260 nm), so the controller 142 activatesthe chemical feed pump 134 to begin metering the concentratedantimicrobial composition into the recycle tank 124. When theconcentration of the antimicrobial in the dilute composition in therecycle tank 124 reaches a desired level, the sensor 136 and, in turn,the controller 142 turn off the chemical feed pump 134. The desiredranges of the concentration of antimicrobial in dilute compositioninclude but are not limited to the concentration ranges of theantimicrobial in the dilute compositions disclosed in U.S. patentapplication Ser. No. 09/494,374 (Compadre et al.). Once the desiredconcentration is obtained in the recycle tank 124, the system pump 146is activated, and the dilute composition is supplied to theantimicrobial application unit 112. The dilute composition provided tothe antimicrobial application unit 112 is not potable. Still,contamination or cross-contamination of the workpieces 120 is not aconcern because of the safety and broad spectrum efficacy of the diluteantimicrobial composition used. The recycle unit 114 supplies the diluteantimicrobial composition to the antimicrobial application unit or units112 at any number of different flow rates and pressures. These flowrates and pressures may include, but are not limited to, the flow ratesand pressures discussed in U.S. Pat. No. 6,742,720.

Once the recycle unit 114 is supplying the dilute antimicrobialcomposition to the antimicrobial application unit 112, the workpieces120 to be processed, such as raw poultry, are moved by the conveyor 116,through the housing 118, and the dilute antimicrobial composition isapplied to the workpieces 120, such as by spraying. The portion of thedilute antimicrobial composition that does not adhere to the workpieces120 collects in a drain and is returned via return line 150, throughfilter 152, and to the recycling tank for reuse. The length of the driptray 122 is selected so that it will catch drops from workpieces 120exiting the housing 118 for approximately 1 minute after the workpieces120 exit the housing 118. This enhances the recovery of the diluteantimicrobial composition and reduces downstream losses. Water spraycurtains may be used in the application chamber, and the workpieces 120may be wet from upstream washing, so additional water will typicallyenter the recycle tank 124.

The sensor 136 continuously monitors the concentration of theantimicrobial in composition in the recycling tank. If the concentrationfalls below a desired amount, the sensor 136 activates the chemical feedpump 134 to add more of the concentrated antimicrobial composition andto bring the concentration of the antimicrobial in the diluteantimicrobial composition back up to the desired level. The system 10can be configured to allow the tap water to be controlled in thisfashion as well, but it is unlikely that there will be a need to addwater. The dilute antimicrobial composition is thereby used repeatedlyto treat any number of units of the workpieces 120 being processed.

At the end of the spray cycle, such as at the end of a shift or a day orother chosen period of time, the valve 148 is actuated to divert thedilute antimicrobial composition received from the system pump 146through capture line 154 to the purge tank 156. The liquid in the purgetank 156 is gravity fed through the drain line 158 to the disposablefilters of the antimicrobial separation unit 160. The disposable filterscapture the antimicrobial to separate the antimicrobial from thecomposition. The antimicrobial impregnated filters are then disposed ofin an appropriate manner, such as by incineration or disposal at anapproved landfill. The remaining, relatively antimicrobial-free liquidis then disposed of in an appropriate manner, such as by being drainedinto a wastewater system of a plant. The frequency with which the system10 will need to be purged will depend upon any number of factors, suchas the number of workpieces 120 to be processed by the antimicrobialapplication unit 112 and the volume of the dilute antimicrobialcomposition required to charge the system 10 at the beginning of a spraycycle. A periodic purge of the system 10 will be used.

FIG. 4 schematically illustrates another embodiment of a capture unit215 including an upstream filter 225 and a downstream filter 227. Thecapture unit 215 may be configured for use with the embodiments of FIGS.1-3, as described above, and may be configured to capture all or aportion of the antimicrobial component of the dilute antimicrobialsolution. For example, at the end of a spray cycle, such as at the endof a shift or a day or other chosen period of time, the system 10 may bepurged of dilute antimicrobial solution. The purging may includeinitiation of a capture sequence or transition to a capture mode thatcoordinates pump and valve operations to thereby direct the diluteantimicrobial solution to the capture unit 215. The central control unit32, 164 may be programmed to sequentially or simultaneously activate ordeactivate one or more system valves or otherwise operate a valve orvalve apparatus in response to purge signal. The purge signal may betransmitted by user or associated with a programmed triggeringcondition, for example. Such triggering conditions may be associatedwith a condition of the dilute antimicrobial solution, an operationalstate of one or more units of the system, the occurrence of apredetermined event (e.g., number of workpieces processed or fixedperiod of time), and/or a variety of other potential triggeringconditions or events. In addition to purging or turning over the system,the central control unit 32, 164 may coordinate transport of diluteantimicrobial solution to the capture unit 215 for processing anddisposal as part of other system operations, which may include aprogrammed response to a triggering event, to, for example, dispose ofdiluted samples used for performing concentration measurements, toadjust the volume of dilute antimicrobial solution circulating throughthe system 10 from the recycle unit 14, 114, to partially turnoversystem fluids to address a low level contamination, or as otherwisedesired.

In one configuration, during a purge of the system 10, the centralcontrol unit 32, 164 may coordinate opening or closing of one or moresystem valves, such as valves 56, 52, 80, or 90 and the powering on oroff of one or more system pumps, such as capture pump 64 or feed pump52, to empty dilute antimicrobial solution into one or more capturelines 221, such as capture lines 60, 100 or even discharge line 100, forprocessing and disposal of the effluent 223. For example, the diluteantimicrobial solution may be released or withdrawn from the recycletanks 42, 124, application unit 12, or the static mixer 96, for example,and may be passed into the capture lines 60, 100, 221 toward the captureunit 215, which may be coupled to the capture line 221 to receive theeffluent 223 for treatment and disposal. The capture unit 215 may beconfigured to process the effluent 223 and thereby capture or otherwiseseparate components of the effluent 223 to render it suitable for safeand cost-effective disposal as wastewater discharge. The components ofthe effluent 223 may include, without limitation, an antimicrobialcomponent at various concentrations, a dilution component such as water,and may include additional components such as contaminants, visibleparticulates, debris, including organic or inorganic particles orbyproducts, any of which may be collectively referred to as solidcomponents herein.

The capture unit 215 may include various upstream and downstream filters225, 227 configured to selectively interact or associate with one ormore components of the effluent 223. In various embodiments, the filters225, 227 may be configured to exploit one or more characteristics of theeffluent 223 or its components to achieve a desired level of separation.For example, the filters 225, 227 may be configured to filter componentsof the effluent 223 based on size, charge, viscosity, consistency,molecular structure, molecular interactions, residues, forces, bonding,diffusion, or any other property or characteristic suitable forfiltering such a component. The filters 225, 227 may include variousfilter layers, meshes, screens, selectively permeable membranes, packedcolumns, fluid beds, one or more stationary or mobile phases, adsorptionmedia, etc. suitable to separate one or more of the components. Forexample, in at least one embodiment, the upstream filter 225 includes asolid separation unit 229 employing a screen filter 225 a configured toseparate solid components 231 from the effluent.

In various embodiments, the resultant upstream filtrate 235 released bythe upstream filter 225 may be passed through a downstream capture line237 a to a capture tank 216. The upstream filtrate 235 may be residentin the capture tank 216 as described above or may pass directly throughto the downstream capture line 237 b. Controlling or monitoring passageof the upstream filtrate 235 toward the downstream filter 227 may beaccomplished using a siphon 102, as described above with respect FIG. 1.A drain or valve may similarly be used to pass the upstream filtrate 235into the downstream capture line 237 b from the capture tank 216. In atleast one embodiment, a pump may be fluidically coupled to thedownstream capture line 237 a, 237 b to transport the upstream effluentfiltrate 235 to the downstream filter 227.

The downstream filter 227 may include an antimicrobial separation unit241 employing a series of at least two filters 227 a, 227 b such ascolumns, barrels, or drums packed with a filter material 243. In onesuch embodiment, the downstream filter 227 comprises an antimicrobialcarbon filtration system including at least two carbon filter units 227a, 227 b configured to retain a filter material 243 that includesactivated carbon. The filter material 243 may be configured to adsorbthe antimicrobial component 245 or other various components, such asundesirable contaminates from the effluent 223. A disposal line 247 maybe coupled to the downstream filter 227 to pass the resultant downstreameffluent filtrate 249 from the downstream filter 227 for disposal. In atleast one embodiment, the capture unit 215 is configured to filter theeffluent 223 such that the downstream effluent filtrate 249 is suitablefor release as wastewater discharge into surface waters or municipalsewage treatment plants.

FIGS. 5-11 illustrate various configurations and features of the captureunit 215. As shown in FIG. 5, the capture unit 215 is configured toreceive effluent 223 sent for capture to the capture unit 215. Thecapture unit 215 is configured to process the effluent 223 through thesolid separation unit 229 and the antimicrobial separation unit 241. Thesolid separation unit 229 may include the upstream filter 225 and theantimicrobial separation unit 241 may include the downstream filter 227.It is to be understood that one or both of the upstream filter 225 andthe downstream filter 227 may include multiple filters aligned in seriesor in parallel. The upstream filter 225 is configured to filter orseparate the solid component 231 from the effluent 223 that mayotherwise interfere with further transport or filtering of the effluent223, e.g., by the downstream filter 227. The solid component 231 mayinclude organic or inorganic materials that may have entered the diluteantimicrobial solution during the application process.

In various embodiments, the solid component 231 may include largeparticles, solids, solids associated with liquids, viscous liquids, fat,gelatinous material, debris, or other materials that may be filteredfrom the effluent via passage through the size restrictive screen filter225 a, shown in cross-section in FIG. 5. Notably, the solid component231 separated from the effluent 223 by the upstream filter 225 couldsimilarly accumulate on the upstream filter 225 thereby clogging theupstream filter 225 and limiting further transport of the effluent 223.Accordingly, the upstream filter 225 may be configured to separate thesolid component 231 while also preventing the filtered solid component231 from accumulating within the fluid path of the effluent 223 where itmay otherwise clog the screen filter 225 a and hinder further transportof the effluent 223. For example, in various embodiments, the upstreamfilter 225 may be positioned at an angle with respect to the directionof effluent flow or may include a series of traps configured to capturethe solid component 231 filtered from the effluent 223. The upstreamfilter 225 may also be movable with respect to the flow path to preventthe solid component 231 separated by the filter 225 a from blocking theflow of effluent 223 through the upstream filter 225. For example, thescreen filter 225 a may include a movable portion that may be slid orrotated from the fluid path such that retained solid component 231 ismoved or rotated out of the flow path with the movable portion whileanother portion of the screen filter 225 a is rotated into the flow pathto filter the effluent 223.

The screen filter 225 a may include a body 253 including a filterportion 255 positioned between ends 257 of the body. The body 253 mayinclude an annular wall 259 defining a bore 261 that extends along arotation axis “R” about which the filter portion 255 is configured torotate as indicated by arrow 273. In various embodiments, the filterportion 255 may be constructed from strips of material patterned orcross-laid to form a plurality of holes or a mesh 263. The body 253 mayalso be constructed from a tube or drum through which perforations areformed to define the holes of the mesh 263 between an inwardly facingsurface 265 and an outwardly facing surface 267 of the annular wall 259.The screen filter 265 is preferably coated with or formed of materialsresilient to corrosion, e.g., anti-corrosives, stainless steel,synthetics, polymers, plastics, ceramics, etc. The holes of the mesh 263may be dimensioned to obstruct passage of the solid component 231 havinga minimum size or cross-section while allowing passage of the remainingeffluent 223. In one preferred embodiment, the holes of the mesh 263 aresized to define cross-sections of about 0.0625 inches, however, the mesh263 may include smaller or larger holes as well as fewer or additionalholes, e.g., in consideration of the amount, size, or retentioncharacteristics the solid components, rate or quantity of effluent,rotation rate or area of the filter portion, etc. In at least oneembodiment, the mesh 263 of the filter portion 255 includes holes havingdifferent sized cross-sections.

The upstream capture line 221 may include an outlet 269 adjacent to anend 257 of the screen filter 225 a that is positioned to delivereffluent 223 into the bore 261. In at least one embodiment, the captureline 221 extends partially within the bore 261 and the outlet 269 mayinclude a downspout directed toward or positioned to deliver theeffluent 223 to a delivery region 271 that extends along an inwardlyfacing surface 265 of the annular wall 259. The delivery region 271 mayinclude a band 275 positioned therealong defining a perimeter of thebore 261. The band may be formed of the same or a different material asthe filter portion 255. The band 275 may have a solid or continuousinwardly facing surface 277 with respect to the bore 261. The inwardlyfacing surface 277 may be smooth to discourage accumulation of solidcomponent 231 or from otherwise obstructing flow of effluent 223 fromthe delivery region 271 toward the filter portion 255. For example, theinwardly facing surface 277 may include a polished metallic surface. Inat least one embodiment, the inwardly facing surface 277 of the band 275may be textured to include grooves or projections. The grooves may beoriented to provide fluid paths for effluent 231 directed toward thefilter portion or to breakup solid components 231. In one embodiment,the inwardly facing surface 277 may be treated or coated with anon-stick material to discourage accumulation of solid component 231. Insome embodiments, the absence of holes defined in the inwardly facingsurface 277 of the band 275 may allow effluent 223 to be delivered intothe bore 261 onto the inwardly facing surface 277 while avoiding forcingaccompanying solid component 231 onto the filter portion 255 where itmay become lodged. As shown in FIGS. 5 and 6, the screen filter 225 amay include bands 275 positioned at both ends 257 of the body 253.However, in at least one embodiment, the screen filter 225 a includesonly one band 275.

The screen filter embodiments shown in FIGS. 5 & 6 include inwardlyfacing surface 265 as well as the portion of the surface 265 thatincludes the inwardly facing surface 277 of the band portion 255 may bepositioned along the horizontal substantially parallel. Upon delivery,the effluent 223 may be directed into the bore 261 such that it may passto the filter portion 255, e.g., due to proximity to the filter portion255 or sufficient momentum. In a further embodiment, a lip or ridge maybe disposed at an end of the body 257 adjacent to the delivery region toprevent effluent 233 from exiting the bore 261 without passing onto thefilter portion 255. In at least one embodiment, however, the inwardlyfacing surface 277 of the band 275 may be positioned at a raised anglewith respect to the horizontal to urge the effluent 223 directed ontothe inwardly facing surface 277 of the band 275 toward the filterportion 255 of the screen filter 225 a. The raised angle may positionthe inwardly facing surface 277 to oppose the direction of effluent 233flow with respect to its release from the outlet 269 to redirect theeffluent 233 toward the filter portion 255 or may complement the generaldirection of flow of the effluent 233 toward the filter portion 255. Inthis or other embodiments, the body 253 of the screen filter 225 a maybe positioned at an angle with respect to the horizontal such that anend 257 is raised relative to the opposing end 257. The angle of thebody 253 may further angle the inwardly facing surface of 265 extendingalong the filter portion 265. Accordingly, the outlet 269 of theupstream capture line 221 may be positioned to release effluent 223 ontothe inwardly facing surface 277 at a high end of the band 275. In theseor other embodiments, the outlet 269 may be angled to direct theeffluent into the bore 261 or onto the inwardly facing surface 277 ofthe band 275 at a perpendicular, parallel, or other angle in-between.

As introduced above, the filter portion 255 of the screen filter 225 amay be configured to rotate about a rotation axis R as generallyidentified by arrow 273. In at least one embodiment, the body 253 of thescreen filter 225 a, which may include the band 275, may also beconfigured to rotate with the filter portion 255. The rotation may bedriven by any suitable mechanism configurable to rotate the filterportion 255 of the screen filter 225 a, such as gears, pulleys, motors,etc. As shown, rotation of the filter portion 255 may be driven byrotation members 279 which may include engagement surfaces 281 such asgears positioned to operatively engage an engagement surface 281 of thescreen filter 225 a and thereon transmit rotation to the filter portion255 or additional portions of the body 253.

As most clearly seen in the cross-section of the screen filter 225 aprovided in FIG. 5, in at least one embodiment, the screen filter 225 aincludes a screw 285 configured to urge effluent 223 through the bore261. For example, the screw 285 may be configured to urge liquidportions of the effluent 223 along the inwardly facing surface 265 ofthe annular wall 259, such as the inwardly facing surface 277 of theband 275, toward the filter portion 255. The screw 285 may also beconfigured to urge solid components 231 along the annular wall 259through the bore 261 toward a solids trap 284. The solids trap 284 may,for example, be located at an end 257 of the body 253 where solidcomponents 231 may be released for disposal. The screw 285 may include athread 287 protruding from the annular wall 259 toward the rotation axisR. The thread 287 may wrap around the annular wall 259 within the bore261 between the ends 257 of the body 253 to form a helix therein. Thethread 287 may be directionally oriented to complement the rotation ofthe filter portion 255 to direct separated solid components 231 towardan end 257 of the bore 261 where the solid components 231 may then bepassed for disposal. For example, the thread 287 may wrap around theinwardly facing surface 265 in a clockwise or counterclockwise directionwith respect to an end 257 of the body 253 to directionally urge solidcomponents 231 toward or away from the end 257 of the body 253 asinduced by the direction of rotation and location of the delivery region265.

In various embodiments, the screen filter 225 a may include or beconfigured for implementation with a cleaning unit 289, as most clearlyseen in FIG. 6. In one form, the cleaning unit 289 may be used to cleanone or more portions of the screen filter 225 a, e.g., dislodge solidcomponents 231 from the annular wall 259 or filter portion 255, provideadditional lubrication to encourage passage of solid components 231through the bore 261, discourage accumulation of solid components 231 onannular wall 259 or filter portion 255, etc. The cleaning unit 289 maybe equipped with a scraper 291 configured to implement cleaningoperations of the cleaning unit 289. The scraper 291 may be positionedwithin or outside the bore 261. In various embodiments, the scraper 291may employ various mechanisms to scrape the screen filter 225 a. Forexample, the scraper 291 may include one or more extensions such asbristles or rigid or elastomeric flaps, for example, configured tocontact the inwardly or outwardly facing surfaces 265, 267 of theannular wall 259 or body 253. In the illustrated embodiment, the scraper291 includes a spray bar 293 having one or more fluid ports 295configured to direct a fluid onto the annular wall 259 to clean thescreen filter 225 a, e.g., to dislodge solid components from the filterportion 255 or encourage solid components 231 to move along a lowerportion of bore 261 by the action of the screw 285. In at least oneembodiment, the spray bar 293 is positioned within the bore 261 todirect fluid onto the inwardly facing surface 265 of the annular wall259, e.g., along the filter portion 255 or bands 275. In someembodiments, multiple spray bars 293 or fluid ports 295 may also bepositioned around the body 253 or both within the bore 261 and along theoutwardly facing surface 267. The fluid ports 295 may include nozzles297 configured to directionally enhance or modulate distribution of thecleaning fluid. In certain embodiments, the fluid ports 295 may bestatically positioned. Regulation of volume or pressure of cleaningfluid directed from the fluid ports 295 may be modulated using pumps,restriction or obstructive elements, valves, etc. For example, in oneembodiment, an orifice plate may be disposed in the spray bar 293. Theorifice plate may be positioned to modulate flow for a single ormultiple fluid ports 295, for example. In at least one embodiment, thefluid ports 295 may be movable via the central control unit 32, 164,e.g., in a predetermined or programmed pattern or selectively, which mayinclude sensors configured to sense locations in need of the cleaningaction of the fluid and that which send such data to the central controlunit 32, 164 for automated directing. In this or another embodiment, thefluid ports 295 may be manually directed via remote controls provided bya user remote control system incorporated with the central control unit32, 164.

In one embodiment, the upstream filter 225 may be configured as amodular unit or pallet for augmentation of a capture unit, such ascapture units 15, 115, of a new or existing application system 10 tothereby filter the solid component 231 of desired size from the effluent223. The upstream filter 225 may therefore include various fittings orattachment points configured to couple to new or existing applicationsystems 10.

The capture unit 215 may further include a capture tank 216. The capturetank 216 may be positioned along the downstream capture line 237 betweenthe upstream and downstream filters 225, 227 and may include a reservoir218 for retaining effluent 223. The capture tank 216 may include aninlet 220 to receive the upstream effluent filtrate 235 from theupstream filter 225. The upstream filter 225 may direct or the inlet 220of the capture tank 216 may be positioned to receive the upstreameffluent filtrate 235 directly from the upstream filter 225, asgenerally shown in FIGS. 5 & 6. For example, the inlet 220 or reservoir218 may be positioned adjacent to and downstream of the filter portion255. In some embodiments, additional capture tanks 216 may be included,e.g., the screen filter 225 a may include a capture tank 216 position tocatch upstream effluent filtrate 235 passed through the filter portion255 which may subsequently be passed to the downstream capture line 237,which may include an additional capture tank 216. In at least oneembodiment, the capture tank 216 is disposed between a first portion ofthe downstream capture line 237 a and a second portion of the downstreamcapture line 237 b, as depicted in FIG. 4.

The capture tank 216 may also include an outlet 222 through whicheffluent 223 may be passed downstream to the downstream filter 227. Theoutlet 220 may be coupled to the downstream capture line 237 and includea drain or valve configured to open the outlet to allow the effluent 223to pass from the capture tank 216 into the downstream capture line 237toward the downstream filter 227. For example, the valve may beconfigured for manual actuation or automated actuation based on a time,volume of upstream effluent filtrate 235 in the reservoir 218, capacityof the downstream filter 227, etc. Automated actuation may be inresponse to a signal provided by the central control unit 32, 164 or thevalve may be mechanically configured to actuate based on a condition ofthe system, e.g., an upstream or downstream pressure.

Transport of the effluent 223 from the outlet 222 toward the downstreamfilter 227 may be promoted, for example, by gravity or a pump disposedin or operatively coupled to the downstream capture line 237. In variousembodiments, the capture tank 216 may include a siphon as shown anddescribed above with respect to FIG. 1. For example, the siphon may befluidically coupled to the downstream capture line 237. The siphon maybe configured to allow the upstream effluent filtrate 235 to collect inthe capture tank 216, until it reaches a desired level, wherein thesiphon thereafter empties or relieves a predetermined volume of theupstream effluent filtrate 235 from the capture tank 216 and passes theeffluent 223 through the downstream capture line 237 toward thedownstream filter 227. By incorporation of the siphon or other mechanismconfigured to avoid continuous passage or trickle of effluent 223, e.g.,using valves configured to be actuated at various time intervals or uponreceiving an actuation signal from the central control unit 32, 164 orsensor configured to monitor the level of effluent in the capture tank216, the capture unit 215 may reduce or eliminate incidences ofchanneling with respect to the downstream filter 227. In at least oneembodiment, however, the capture unit 215 does not incorporate a siphonor other mechanism configured to avoid continuous passage of effluent223. In one such embodiment, the capture unit 215 does not include acapture tank 216, rather the downstream capture line 237 is positionedto collect the upstream effluent filtrate 235 from the screen filter 225a and pass the upstream effluent filtrate 235 directly to the downstreamfilter 227 for continuous processing of the effluent 223 transported tothe capture unit 215. As such, the capture unit 215 may be configuredfor continuous capture and disposal of effluent 223.

The downstream filter 227 may include an antimicrobial separation unit241 as described above and generally shown in FIGS. 4-6. Theantimicrobial separation unit 241 may include one or more filter units227 a, 227 b, such as disposable carbon filters 108, as described abovewith respect to FIG. 1, for selective removal of the antimicrobialcomponent 228 from the effluent 223, wherein the antimicrobial ispreferably a quaternary ammonium compound, an alkylpyridinium chloride,or cetylpyridinium chloride. Intermediate filter line 239 extendsbetween the filter units 227 a, 227 b for transporting intermediateeffluent filtrate 249 from filter unit 227 a to filter unit 227 b. Asdescribed above, the filter units 227 a, 227 b may be configured toexploit one or more characteristics of the effluent 223 or itscomponents to achieve the desired separation of the antimicrobialcomponent 245 from the effluent 223 using any suitable filter strategyand design. In the illustrated embodiment, the filter units 227 a, 227 bof the separation unit 241 of the downstream filter 227 include at leasttwo filter units that are aligned in series. Each filter unit 227 a, 227b includes a container 242 for housing a filter material 243, such asactivated carbon, through which the upstream effluent filtrate 235 maybe passed for separation of the antimicrobial microbial component 245,e.g., via reaction or adsorption onto the filter material 243. While twofilters units 227 a, 227 b are shown, additional filters may be used.For example, in one embodiment, the downstream filter 227 includes aseparation unit 241 having between two and four filter units 227 a, 227b aligned in series, wherein each filter unit 227 a, 227 b includes acontainer for retaining a supply of filter material 243 includingactivated carbon.

The downstream filter 227 may include an outlet configured to be coupledto a disposal line 247 to allow downstream effluent filtrate 249 to exitthe separation unit 241. In various embodiments, the separation unit 241is configured to separate a suitable quantity of antimicrobial component245 from the upstream effluent filtrate 235 such that the resultantdownstream effluent filtrate 249 is characterized as having suitably lowlevels of contaminants or antimicrobial component 245 such that thedownstream effluent filtrate 249 is suitable for disposal as plantwastewater discharge in compliance with current effluent guidelines.

In various embodiments, and in further reference to FIG. 7, theantimicrobial separation units 106, 160, 241 may include a header 250.The header 250 is preferably configured to distribute effluent 223, suchas upstream or an intermediate downstream effluent filtrate 235, 249,evenly with respect to the filter material 243, however, in at least oneembodiment, the header 250 may be configured to selectively distributethe effluent 223 to one or more regions of the filter material 243within the container 242. The header 250 includes a body 252 defining aninternal fluid path 254 that extends between an upstream inlet 256 and aplurality of downstream fluid ports 258. The body 252 may include one ormore arms 260 into which fluid ports 258 may be formed to distribute theeffluent 223. The arms 260 may include various arrangements of fluidports 258 patterned thereon. In the illustrated embodiment, the header250 includes four arms 260, and may be constructed from piping, forexample, and arranged in a crossing or “X” configuration. In otherembodiments, however, the header 250 may include other configurationswith fewer or additional arms, which may further include secondary arms.

The fluid ports 258 are aligned along two sides of each arm 260.However, in some embodiments, the fluid ports 258 may be aligned along asingle side, circumferentially, or along three or more sides of the arms260 or as otherwise desired to distribute the effluent 223 of effluentfiltrate 235, 249 and reduce channeling. For example, as introducedabove, even distribution may be desirable to prevent channeling or toincrease surface contact between the effluent 223 and the filtermaterial 243. The number and dimensions of the fluid ports 258 may varyto optimize distribution, for example, in consideration of thecharacteristics of the fluid, filter material 243, or flow conditions.As such, the fluid ports 258 may be dimensioned to restrict, direct,spray, or focus the fluid exiting the fluid path 254. As shown, each ofthe arms includes twenty-six fluid ports 258. In at least oneembodiment, each of two or more arms 260 includes twenty fluid ports. Asshown, the header 250 also includes fluid ports 258 havingcross-sections between 0.125 to 0.250 inches. However, as describedabove, additional dimensions and features could also be used dependingon the environment in which the system 10 operates. For example, in oneembodiment, the header 250 is configured to be movable to increasedispersion of the effluent 223. For instance, the header 250 may beadapted to rotate or selectively move according to a pre-determinedpattern. The rate or degree of movement for example may be related tothe amount of effluent 223 passing through the header.

FIG. 8 illustrates the header 250 positioned in the filter unit 227 ashown in FIGS. 4-6 according to various embodiments. The header 250 maybe employed in a carbon filtration system including at least two filterunits 227 a, 227 b, 108, as described above. It is to be appreciated,however, that filter units 227 a, 227 b, 108 do not necessarily includea header 250 or the illustrated header 250. Indeed, in at least oneembodiment, filter units 227 a, 227 b, 108 include different headers.Similarly, the filter units 227 a, 227 b, 108 may be configured toretain the same or different filter material 243. In one embodiment, oneor both of the filter units 227 a, 227 b shown in FIG. 5 may include theheader 250. As described above, the filter units 227 a, 227 b, 108 mayinclude containers 242 configured to retain filter material 243. Thecontainer may include an inner surface 272 or liner 274 configured to bepositioned adjacent to the filter material 243. The header 250 may besuitably positioned at an upstream portion of the container 242 toreceive upstream effluent filtrate 235 from the downstream capture line237 or an intermediate downstream effluent filtrate 249 from theintermediate filter line 239, as the case may be, and therein distributethe fluid onto the filter material 243. In the illustrated embodiment,the inlet 256 of the header 250 is configured to couple to thedownstream capture line 237 to receive the upstream effluent filtrate235 within the fluid path 254. The header 250 is positioned over thefilter material 243 and is configured to distribute the upstreameffluent filtrate 249 onto the filter material 243 positioned within thecontainer 242. In operation, the header 250 may be attached to or bepositioned within the container 242, which may include a filter drum forexample. Distribution provided by the header 250 may reduce or inhibitchanneling through the container 242. For example, the header 250 maydistribute or sprinkle received effluent 223 or effluent filtrate 235,249 over a top surface of the filter material 243 to thereby achieveincreased distribution and little to no channeling through the filtermaterial 243.

In various embodiments, the antimicrobial separation units 106, 160, 241may include a filter unit 227 a, 227 b, 108 in which the container 242includes a plastic or plastic lined drum configured to contain filtermaterial 243 comprising activated carbon. As described above, the filterunit 227 a, 227 b, 108 may be disposable such that the activated carbonmay be properly disposed of when spent. In contrast to conventionalfilter units 227 a, 227 b, 108 and containers 242, which are typicallyformed of metals susceptible to corrosion during their operationallifetime in a capture unit 15, 115, 215, the plastic drum may beconfigured to avoid such corrosion that may otherwise lead to theoccurrence of leaks.

FIGS. 9-11 illustrate embodiments of containers 242 suitable for use inthe filter units 227 a, 227 b, 108 described above for improvedintegrity of the system 10 or an antimicrobial carbon filtration system.As introduced above, conventional metallic containers, commonly referredto as drums, used in filter units 227 a, 227 b, 108 have been found tobe susceptible to premature loss of integrity during their operationallifetimes. This loss of integrity is believed to be a result ofcorrosion produced in the corrosive environment of the antimicrobialseparation unit 241. In the embodiments illustrated in FIGS. 9-11, thecontainers 242 include inner surfaces 272 or liners 274 composed of anon-corrosive material.

FIG. 9 illustrates a container 242 having an outer surface 270 and aninner surface 272. The outer surface 270 may include a conventionalmetallic material. In other embodiments, however, the outer surface 272may include a hard plastic, a ceramic, a rigid material, or othersuitable material. The inner surface 272 may include a coating formedalong a container shell or outer surface 270 material. The coating mayinclude a plastic, polymer, resin, enamel, ceramic, epoxy,anti-corrosive, or a combination or blend thereof.

FIG. 10 illustrates an alternate embodiment of the container 242 whereinthe inner surface 272 is formed as a liner 274. The liner 274 may beconfigured to be selectively inserted and removed from within the outersurface 270. In one embodiment, the liner 274 and the inner surface 272may be further formed of a resilient elastomeric material that may becompressably retained within the outer surface 270. Other manners ofretaining the inner surface 272 within the outer surface 270 may includefittings adhesives, flanges, brackets, or fittings employing latches,threads, clamps, bolts, hooks and grooves, or screws, for example.

FIG. 11 illustrates another embodiment of the container 242 wherein boththe inner and outer surfaces 270, 272 may be formed of the materialsdescribed above with respect to FIGS. 9 and 10. For example, thecontainer 242 may include a plastic drum configured to retain filtermaterial 243, such as activated carbon.

It is to be appreciated that the choice of inner surface material in theembodiments illustrated in FIGS. 9-11 should be one that is preferablyresistant to integrity damaging corrosion during its operationallifetime within its operational environment. For example, the innersurface material should be resistant to corrosion within the environmentproduced by the effluent 223 or when the effluent 223 mixes or reactswith filter material comprising activated carbon.

Other modifications, changes and substitutions are intended in theforegoing, and in some instances, some features will be employed withouta corresponding use of other features. For example, the differentfeatures of the alternate embodiments may be merged or combined in anynumber of different combinations. Also, the antimicrobial applicationunit 12 may take any number of forms, shapes, and sizes and need not beone of the spray cabinet embodiments disclosed in U.S. Pat. No.6,742,720. Similarly, any number of different compositions may be usedin any number of different concentrations, and the compositions may ormay not include one or more antimicrobials. Further still, additionalpumps, filters, and similar components may be incorporated into thesystem 10. Also, any number of different methods may be used to monitorthe composition of the composition in the recycle tank 24. Similarly,the composition may be monitored constantly or at desired intervals.Further still, the drip tray 22 may not be used and may be any number ofdifferent lengths. Of course, quantitative information is included byway of example only and is not intended as a limitation as to the scopeof the invention. Accordingly, it is appropriate that the invention beconstrued broadly and in a manner consistent with the scope of theinvention disclosed.

This specification has been written with reference to variousnon-limiting and non-exhaustive embodiments. However, it will berecognized by persons having ordinary skill in the art that varioussubstitutions, modifications, or combinations of any of the disclosedembodiments (or portions thereof) may be made within the scope of thisspecification. Thus, it is contemplated and understood that thisspecification supports additional embodiments not expressly set forth inthis specification. Such embodiments may be obtained, for example, bycombining, modifying, or reorganizing any of the disclosed steps,components, elements, features, aspects, characteristics, limitations,and the like, of the various non-limiting and non-exhaustive embodimentsdescribed in this specification. In this manner, Applicant reserves theright to amend the claims during prosecution to add features asvariously described in this specification, and such amendments complywith the requirements of 35 U.S.C. §§ 112(a) and 132(a).

What is claimed is:
 1. A method for capturing an antimicrobial componentof an antimicrobial solution, comprising: filtering a solid componentfrom an antimicrobial solution with a first filter coupled to a captureline for carrying the antimicrobial solution to the first filter;conveying the antimicrobial solution from the first filter to a secondfilter; filtering an antimicrobial component from the antimicrobialsolution with the second filter; wherein the first filter comprises ascreen filter having a rotatable body, wherein the body comprises anannular wall having an inwardly facing surface defining a bore toreceive the antimicrobial solution from the capture line, and whereinthe annular wall comprises: a filter portion defining a plurality ofholes along the inwardly facing surface that extend through the annularwall to filter the solid component of the antimicrobial solution whenthe antimicrobial solution is received thereon from the capture line,and a band portion having a continuous surface that extends about thebore along the inwardly facing surface to receive the antimicrobialsolution from the capture line onto the continuous surface before theantimicrobial solution is received along the filter portion, and whereinthe capture line comprises an outlet positioned to direct theantimicrobial solution onto the continuous surface of the band at anangle between less than parallel and perpendicular to the inwardlyfacing surface.
 2. The method of claim 1, wherein the screen filterfurther comprises a thread protruding from the inwardly facing surfaceof the annular wall into the bore, and wherein the thread helicallyextends along the inwardly facing surface between a first end and asecond end of the body.
 3. The method of claim 2, wherein the threadextends along the filter portion and the continuous surface.
 4. Themethod of claim 1, further comprising the filtered solid component fromthe annular wall with a cleaner associated with the screen filter. 5.The method of claim 4, wherein the cleaner comprises a spray barincluding one or more fluid ports positioned to direct fluid toward anoutwardly facing surface of the annular wall.
 6. The method of claim 5,wherein the fluid ports are positioned outside the bore.
 7. The methodof claim 1, wherein the second filter comprises at least two filterunits connected by intermediate filter lines, wherein each filter unitcomprises a container retaining a filter material comprising activatedcarbon, wherein the filter units are aligned in series and areconfigured to filter the antimicrobial component from the antimicrobialsolution, and wherein the antimicrobial component comprises a quaternaryammonium compound.
 8. The method of claim 7, wherein the antimicrobialcomponent is selected from the group consisting of alkylpyridiniumchloride and cetylpyridinium chloride.
 9. The method of claim 7, whereinat least one of the filter units includes a header comprising a bodyhaving an upstream inlet and a plurality of downstream fluid portspositioned along a plurality of arms.
 10. The method of claim 9, whereinthe body comprises at least four arms arranged in an “X” configuration.11. The method of claim 10, wherein the body includes at least two arms,each defining at least twenty fluid ports.
 12. The method of claim 11,wherein the fluid ports are positioned on at least two sides of eacharm.
 13. The method of claim 11, wherein the fluid ports definecross-sections between 0.125 to 0.250 inches.
 14. The method of claim 9,wherein the fluid ports are dimensioned to restrict, direct, spray, orfocus the fluid exiting from the fluid ports.
 15. The method of claim 9,wherein the header is movable or rotatable to increase dispersion of thefluid exiting from the fluid ports.
 16. The method of claim 7, whereinat least one of the containers comprises an inner surface formed of aplastic.
 17. The method of claim 1, wherein the solid component isfiltered from the antimicrobial solution by the first filter based on aproperty or characteristic of the solid component selected from thegroup consisting of size, charge, viscosity, consistency, molecularstructure, molecular interactions, residues, forces, bonding, anddiffusion.
 18. The method of claim 1, wherein the solid component isselected from the group consisting of large particles, solids, solidsassociated with liquids, viscous liquids, fat, gelatinous material anddebris.
 19. The method of claim 1, wherein the antimicrobial solution isconveyed by gravity from the first filter to the second filter.
 20. Themethod of claim 1, wherein the antimicrobial solution is pumped from thefirst filter to the second filter.